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Feature
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Design Recommendation
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Notes / Best Practices
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Tolerances
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Apply tight tolerances only where functionally necessary
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Looser tolerances reduce cost and lead time without sacrificing function.
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Wall Thickness
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Maintain a minimum wall thickness of ≥1 mm for metals
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Thin walls can vibrate or deform during machining.
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Hole Sizes
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Design standard hole sizes (e.g., Ø3, Ø6, Ø10 mm)
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Standard drill sizes are more economical and faster to machine.
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Hole Depths
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Keep depth ≤3× diameter for blind holes
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Deeper holes require special tools or peck drilling.
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Internal Radii
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Use fillets with radius ≥0.5 mm in internal corners
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Sharp corners are hard to machine and increase tool wear.
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Undercuts
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Avoid or clearly specify undercuts
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Requires custom tools or secondary operations.
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-ed Features
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Use standard thread sizes (e.g., M6, ¼-20) and avoid threads too close to edges
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Allow adequate clearance for tool engagement.
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Flatness & Parallelism
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Specify only when critical for function
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Can increase machining time; use GD&T where appropriate.
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Surface Finish
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Match to function (e.g., Ra 1.6–3.2 µm for most metal parts)
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Finer finishes often require grinding, polishing, or slow machining passes.
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Part Symmetry
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Use symmetrical designs when possible
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Aids in fixturing and reduces setup complexity.
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Text/Logos
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Use engraved text ≥0.5 mm deep, with simple fonts
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Small or decorative fonts may not machine cleanly.
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Material Choice
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Select materials based on strength and machinability
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Examples: 6061-T6 aluminum (easy), stainless steel (difficult).
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